Automated load cell identification

ABSTRACT

Aspects of the present relate to automated load cell identification. A method is provided. The method generally includes sending, from a load cell to a remote processing system, identification information associated with the load cell; and determining whether the load cell is valid for use during makeup of a threaded connection of a first threaded tubular to a second threaded tubular based on the identification information associated with the load cell. The load cell identification information may include a measurement range of torque values supported by the load cell. The method can include comparing the measurement range of torque values to a job defined range of torque values associated with the makeup of the threaded connection; and determining that the load cell is valid for use based on the comparison. The identification information can be used to detect the load cell type, range, and calibration data before tubular makeup to ensure data quality and safety at work.

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The present disclosure generally relates to makeup tools and, morespecifically, to automated load cell identification to detect the loadcell type, range, and calibration data before tubular makeup to ensurethe data quality.

Description of the Related Art

In wellbore construction and completion operations, a wellbore is formedto access hydrocarbon-bearing formations (e.g., crude oil and/or naturalgas) by the use of drilling. Drilling is accomplished by utilizing adrill bit that is mounted on the end of a drill string. To drill withinthe wellbore to a predetermined depth, the drill string is often rotatedby a top drive or rotary table on a surface platform or rig, or by adownhole motor mounted towards the lower end of the drill string. Afterdrilling to a predetermined depth, the drill string and drill bit areremoved and a string of casing is lowered into the wellbore. An annulusis thus formed between the casing string and the formation. The casingstring is temporarily hung from the surface of the well. A cementingoperation is then conducted in order to fill the annulus with cement.The casing string is cemented into the wellbore by circulating cementinto the annulus defined between the outer wall of the casing and theborehole. The combination of cement and casing strengthens the wellboreand facilitates the isolation of certain areas of the formation behindthe casing for the production of hydrocarbons.

A drilling rig is constructed on the earth's surface or floated on waterto facilitate the insertion and removal of tubular strings (e.g., drillpipe, casing, sucker rod, riser, or production tubing) into a wellbore.The drilling rig includes a platform and power tools, such as anelevator and slips, to engage, assemble, and lower the tubulars into thewellbore. The elevator is suspended above the platform by a draw worksthat can raise or lower the elevator in relation to the floor of therig. The slips are mounted in the platform floor. The elevator and slipsare each capable of engaging and releasing a tubular and are designed towork in tandem. Generally, the slips hold a tubular or tubular stringthat extends into the wellbore from the platform. The elevator engages atubular joint and aligns it over the tubular string being held by theslips. One or more power drives, e.g. a power tong and a spinner, arethen used to thread the joint and the string together. Once the tubularsare joined, the slips disengage the tubular string and the elevatorlowers the tubular string through the slips until the elevator and slipsare at a predetermined distance from each other. The slips then reengagethe tubular string and the elevator disengages the string and repeatsthe process. This sequence applies to assembling tubulars for thepurpose of drilling, deploying casing, or deploying other componentsinto the wellbore. The sequence is reversed to disassemble the tubularstring.

During operations, the threaded connections can be monitored to ensurethat the connections are good. Load cells can be used to measureinformation force data. The information can be provided to a controlsystem. The control system can process the information and can providean output, for example, to a display. An operator can view the displayand make decisions regarding the threaded connections. In some cases,the control system can also take input from the operator.

In order to reduce the possibility of human error and to increaseefficiency, it is desirable to automate the process of load cellidentification and information related to the load cell, in order toverify the load cell and ensure data quality during make up.

SUMMARY OF THE DISCLOSURE

The present disclosure generally relates to automated load cellidentification, which may include information such as the load celltype, the load cell range, unique serial number and calibration data ofthe load cell. The load cell identification information may be sent to aremote processor before a tubular makeup to ensure the data quality.

In one aspect, a method of automated load cell identification isprovided. The method generally includes sending, from a load cell to aremote processing system, identification information associated with theload cell and determining whether the load cell is valid for use duringmakeup of a threaded connection of a first threaded tubular to a secondthreaded tubular based on the identification information associated withthe load cell.

In another aspect, a tubular makeup system is provided. The tubularmakeup system generally includes a load cell and a remote processingsystem in communication with the load cell, wherein: the load cell isconfigured to sending identification information associated with theload cell to the remote processing system; and the remote processingsystem is configured to determine whether the load cell is valid for useduring makeup of a threaded connection of a first threaded tubular to asecond threaded tubular based on the identification informationassociated with the load cell.

Aspects generally include methods, apparatus, systems, computer readablemediums, and processing systems, as substantially described herein withreference to and as illustrated by the accompanying drawings.

To the accomplishment of the foregoing and related ends, the one or moreaspects comprise the features hereinafter fully described andparticularly pointed out in the claims. The following description andthe annexed drawings set forth in detail certain illustrative featuresof the one or more aspects. These features are indicative, however, ofbut a few of the various ways in which the principles of various aspectsmay be employed, and this description is intended to include all suchaspects and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentdisclosure can be understood in detail, a more particular description ofthe disclosure, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this disclosure and are therefore not to beconsidered limiting of its scope, for the disclosure may admit to otherequally effective embodiments.

FIG. 1A is a partial cross section view of a connection between threadedpremium grade tubulars.

FIG. 1B is a partial cross section view of a connection between threadedpremium grade tubulars in a seal position formed by engagement betweensealing surfaces.

FIG. 1C is a partial cross section view of a connection between threadedpremium grade tubulars in a shoulder position formed by engagementbetween shoulder surfaces.

FIG. 2A illustrates an ideal torque-turns curve for the premiumconnection.

FIG. 2B illustrates an ideal torque gradient-turns curve for the premiumconnection.

FIG. 3A is a perspective view of a tong assembly in an upper position.

FIG. 3B is a block diagram illustrating a tubular makeup system.

FIG. 4 illustrates an example tubular makeup system including a loadcell that sends identification information, in accordance with certainaspects of the present disclosure.

FIG. 5 is a block diagram illustrating example operations of the loadcell illustrated in FIG. 4, in accordance with certain aspects of thepresent disclosure.

FIG. 6 is a flow diagram illustrating example operations for automatedload identification before makeup of a threaded connection, inaccordance with certain aspects of the present disclosure.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed in one aspectmay be beneficially utilized on other aspects without specificrecitation.

DETAILED DESCRIPTION

Aspects of the present disclosure generally relate to automated loadcell identification. For example, tubular makeup can include use ofpower tongs. However, the aspects of this disclosure for automated loadcell identification are not limited to this system, but could be usedfor automated load cell identification in any system using load cells.The power tongs (or other system) may include load cells to measureforce applied to connections during the tubular makeup (or otherconnections, such as casing, etc., duration a makeup process). The loadcells may be in communication with a remote processing system, which maybe on-site, in a nearby operator room, or off-site.

The remote processing system may be used to analyze the measurements,such as force measurements by the load cell during a tubular makeup. Theremote processing system may perform such functions as providingoutputting information to a display, such as graphical representationsof calculated torque, alerts or status message to an operator related toquality of the connections in the system, or even automated control ofthe system based on the measurements. In some cases, the remoteprocessing system uses other processing systems, clients, or programs toperform some of the functions described above. In some cases, the remoteprocessing system is operated by, or takes some input, from an operatoror technician. FIGS. 1-3 below illustrate one example of a tubularmakeup system in communication with a processing system with a graphicalevaluator, in which aspects of the present disclosure may be applied.

Techniques and apparatus are provided herein for automated load cellidentification, which may reduce the need for manual input from theoperator/technician in these types of systems, which in turn may reduceerrors in torque calculations and lead to improved and more efficientevaluations of connections.

Example Graphical Evaluator for Tubular Makeup

FIG. 1A illustrates a connection 1 between premium grade tubulars 2, 4.The tubulars 2, 4 may be any oil country tubular good, such asproduction tubing, casing, liner, or drill pipe. The connection 1 mayinclude a first tubular 2 joined to a second tubular 4 through a tubularcoupling 6. Each of the tubulars 2, 4 and the coupling 6 may be madefrom a metal or alloy, such as plain carbon steel, low alloy steel, highstrength low alloy steel, stainless steel, or a nickel based alloy. Theend of each tubular 2, 4 may have a tapered externally-threaded surface8 (aka a pin) which co-operates with a correspondingly taperedinternally-threaded surface (aka box) 10 on the coupling 6. Each tubular2, 4 may be provided with a torque shoulder 12 which co-operates with acorresponding torque shoulder 14 on the coupling 6. At a terminal end ofeach tubular 2, 4, there may be defined an annular sealing area 16 whichis engageable with a co-operating annular sealing area 18 definedbetween the tapered portions 10, 14 of the coupling 6. Alternatively,the sealing areas 16, 18 may be located at other positions in theconnection 1 than adjacent the shoulders 12, 14.

During makeup, the box 10 is engaged with the pin 8 and then screwedonto the pin by relative rotation therewith. During continued rotation,the annular sealing areas 16, 18 contact one another, as shown in FIG.1B. This initial contact is referred to as the “seal position”. As thecoupling 6 is further rotated, the co-operating tapered torque shoulders12, 14 contact and bear against one another at a machine detectablestage referred to as a “shoulder position”, as shown in FIG. 1C. Theincreasing pressure interface between the tapered torque shoulders 12,14 cause the seals 16, 18 to be forced into a tighter metal-to-metalsealing engagement with each other causing deformation of the seals 16and eventually forming a fluid-tight seal.

FIG. 2A illustrates an ideal torque-turns curve 50 for the premiumconnection. FIG. 2B illustrates an ideal torque gradient-turns curve 50a for the premium connection. During makeup of the tubulars 2, 4, torqueand turns measurements may be recorded and the curves 50, 50 a displayedfor evaluation by a technician. Shortly after the coupling 6 engages thetubular 4 and torque is applied, the measured torque increases linearlyas illustrated by curve portion 52. As a result, corresponding curveportion 52 a of the differential curve 50 a is flat at some positivevalue.

During continued rotation, the annular sealing areas 16, 18 contact oneanother causing a slight change (specifically, an increase) in thetorque rate, as illustrated by point 54. Thus, point 54 corresponds tothe seal position shown in FIG. 1B and is plotted as the first step 54 aof the differential curve 50 a. The torque rate then again stabilizesresulting in the linear curve portion 56 and the plateau 56 a. Inpractice, the seal condition (point 54) may be too slight to bedetectable. However, in a properly behaved makeup, adiscernable/detectable change in the torque rate occurs when theshoulder position is achieved (corresponding to FIG. 1C), as representedby point 58 and step 58 a. The torque rate then again increases linearlyas illustrated by curve portion 60 and the plateau 60 a until makeup ofthe connection is terminated at final torque 62.

FIG. 3A is a perspective view of a power drive, such as tong assembly100, in an upper position. A group 140 g of clamps has been removed forillustrative purposes. The tong assembly 100 may include a power tong102 and a back-up tong 104 located on a drilling rig 106 coaxially witha drilling center 108 of the drilling rig 106. The assembly 100 may becoupled in a vertically displaceable manner to one or more guide columns110 (two shown) arranged diametrically opposite each other relative tothe drilling centre 108. The guide columns 110 may be connected to achassis 112 which by wheels 114 and hydraulic motors (not shown) may bedisplaced horizontally on rails 116 connected to the drilling rig 106.In the operative position, the assembly 100 may be located immediatelyabove the slips 118 of the drilling rig 106.

The power tong 102 may include a power tong housing provided with athrough aperture that corresponds to the guide columns 110, and anundivided drive ring connected via a bearing ring (not shown). Thebearing ring may have a toothed ring (not shown) in mesh with cogwheels(not shown) on one or more hydraulic motors (not shown), such as two.One of the motors may be a spinner motor (high speed, low torque) andthe other motor may be one or more torque motors (high torque, lowspeed). The toothed ring may be coupled to the drive ring byscrew-bolt-joints (not shown). The hydraulic motors may be arranged torotate the drive ring about the drilling centre 108. The two hydraulicmotors may be disposed on diametrically opposite sides of the drivering. A cover may be provided to cover the power tong housing.

In the drive ring and co-rotating with this may be two crescent-shapedgroups 140 g (only one shown) of clamps. Each group 140 g of clamps maybe provided with one or more, such as three, clamps distributed aroundthe drilling center 108. Each clamp may include a cylinder blockprovided with one or more, such as three, cylinder bores arranged in avertical row. In each cylinder bore may be a correspondinglongitudinally displaceable piston that seals against the cylinder boreby a piston gasket. A rear gasket may prevent pressurized fluid fromflowing out between the piston and the cylinder bore at the rear end ofthe piston.

The pistons may be fastened to the housing of the group 140 g of clampsby respective screw-bolt-joints. On the part of the cylinder blockfacing the drilling center 108 there may be provided a gripper. Thegripper may be connected to the cylinder block by fastening, such aswith dovetail grooves or screw-bolt-joints (not shown). Surrounding thedrive ring there may be provided a swivel ring that seals by swivelgaskets, the swivel ring may be stationary relative to the power tonghousing. The swivel ring may have a first passage that communicates withthe plus side of the pistons via a first fluid connection, a secondpassage that communicates with the minus side of the pistons via asecond fluid connection, and a further passage. The cylinder and thepiston may thereby be double acting. The swivel ring, swivel gaskets anddrive ring may together form a swivel coupling.

The backup tong 104 may also include the clamp groups. The back-up tong104 may further include a back-up tong housing with guides 176 thatcorrespond with the guide columns 110, and a retainer ring for twogroups of clamps. At the guides 176 there may be cogwheels that meshwith respective pitch racks of the guide columns 110. Separate hydraulicmotors may drive the cogwheels via gears. A pair of hydraulic cylindersmay be arranged to adjust the vertical distance between the power tong102 and the back-up tong 104.

In operation, when the tubular joint 2 is to be added to tubular string20 (already including tubular joint 4), the assembly 100 may bedisplaced vertically along the guide columns 110 by the hydraulicmotors, the gears, the cogwheels and the pitch racks until the back-uptong 104 corresponds with the pin 8 of the tubular string 20. The box 10of the coupling 6 may have been madeup to the pin 8 of the joint 2offsite (aka bucking operation) before the tubulars 2, 4 are transportedto the rig. Alternatively the coupling 6 may be bucked on the joint 4instead of the joint 2. Alternatively, the coupling 6 may be welded toone of the tubulars 2, 4 instead of being bucked on.

The vertical distance between the back-up tong 104 and the power tong102 may be adjusted so as to make the grippers correspond with thecoupling 6. The clamps may be moved up to the coupling 6 by pressurizedfluid flowing to the first passage in the swivel ring and on through thefirst fluid connection to the plus side of the pistons. The excess fluidon the minus side of the pistons may flow via the second fluidconnection and the second passage back to a hydraulic power unit (notshown).

The grippers may then grip their respective pin or box while thehydraulic motors rotate the drive ring and the groups 140 g of clampsabout the drilling center 108, while at the same time constant pressuremay be applied through the swivel ring to the plus side of the pistons.The power tong 102 may be displaced down towards the back-up tong 104while the screwing takes place. After the desired torque has beenachieved, the rotation of the drive ring may be stopped. The clamps maybe retracted from the tubular string 20 by pressurized fluid beingdelivered to the minus side of the pistons via the swivel ring. Theassembly 100 may be released from the tubular string 20 and moved to itslower position.

When a joint 2 is to be removed from the tubular string 20, theoperation is performed in a similar manner to that described above. Whentools or other objects of a larger outer diameter than the tubularstring 20 are to be displaced through the assembly 100, the grippers mayeasily be removed from their respective clamps, or alternatively thegroups 140 g of clamps can be lifted out of the drive ring.

Alternatively, other types of tong assemblies may be used instead of thetong assembly 100.

FIG. 3B is a block diagram illustrating a tubular makeup system 200,according to one embodiment of the present disclosure. The tubularmakeup system 200 may include the tong assembly 100, a tong remote unit(TRU) 204, a turns counter 208, a torque cell 212, and the controlsystem 206. The control system 206 may communicate with the TRU 204 viaan interface. Depending on sophistication of the TRU 204, the interfacemay be analog or digital. Alternatively, the control system 206 may alsoserve as the TRU.

A programmable logic controller (PLC) 216 of the control system 206 maymonitor the turns count signals 210 and torque signals 214 from therespective sensors 208, 212 and compare the measured values of thesesignals with predetermined values 223-230. In aspects, the PLC 216 maybe any type of embedded computer device, for example, the PLC 216 may bereplaced by a microcontroller unit (MCU), field programmable gate array(FPGA), application specific integrated circuit (ASIC), applicationspecific instruction set processor (ASIP), digital signal processor(DSP), etc. The predetermined values 223-230 may be input by antechnician for a particular connection. The predetermined values 223-230may be input to the PLC 216 via an input device 218, such as a keypad orany touch sensitive display.

Illustrative predetermined values 223-230 which may be input, by antechnician or otherwise, include minimum and maximum delta gradientvalues 223, a shoulder threshold gradient 224, a dump torque value 226,minimum and maximum delta turns values 228, minimum and maximum torquevalues 230, and reference curve data 242. The minimum and maximum torquevalues 230 may include a set for the shoulder position and a set for thefinal position. The torque values 230 may be derived theoretically, suchas by finite element analysis, or empirically, such as by laboratorytesting and/or analysis of historical data for a particular connection.The dump torque value 226 may simply be an average of the final minimumand maximum torque values 230. During makeup of the connection 1,various output may be observed by an technician on output device, suchas a video monitor, which may be one of a plurality of output devices220. A technician may observe the various predefined values which havebeen input for a particular connection. Further, the technician mayobserve graphical information such as the torque rate curve 50 and thetorque rate differential curve 50 a. The plurality of output devices 220may also include a printer such as a strip chart recorder or a digitalprinter, or a plotter, such as an x-y plotter, to provide a hard copyoutput. The plurality of output devices 220 may further include analarm, such as a horn or other audio equipment, to alert the technicianof significant events occurring during makeup, such as the shoulderposition, termination, and/or a violation of a criterion.

Upon the occurrence of a predefined event(s), the PLC 216 may output adump signal 222 to the TRU 204 to automatically shut down or reduce thetorque exerted by the tong assembly 100. For example, dump signal 222may be issued in response to the measured torque value reaching the dumptorque 226 and/or a bad connection.

The comparison of measured turn count values and torque values withrespect to predetermined values is performed by one or more functionalunits of the PLC 216. The functional units may generally be implementedas hardware, software or a combination thereof. The functional units mayinclude one or more of a torque-turns plotter algorithm 232, a processmonitor 234, a torque gradient calculator 236, a smoothing algorithm238, a sampler 240, a database 242 of reference curves, a connectionevaluator 252, and a target detector 254. The process monitor 234 mayinclude one or more of a thread engagement detection algorithm 244, aseal detection algorithm 246, a shoulder detection algorithm 248, and agraphical evaluator algorithm 250. Alternatively, the functional unitsmay be performed by a single unit. As such, the functional units may beconsidered logical representations, rather than well-defined andindividually distinguishable components of software or hardware.

In operation, one of the threaded members (e.g., tubular 2 and coupling6) is rotated by the power tong 102 while the other tubular 4 is held bythe backup tong 104. The applied torque and rotation are measured atregular intervals throughout the makeup. The frequency with which torqueand rotation are measured may be specified by the sampler 240. Thesampler 240 may be configurable, so that an technician may input adesired sampling frequency. The torque and rotation values may be storedas a paired set in a buffer area of memory. Further, the rate of changeof torque with respect to rotation (hereinafter “torque gradient”) maybe calculated for each paired set of measurements by the torque gradientcalculator 236. The smoothing algorithm 238 may operate to smooth thetorque-turns curve 50 and/or torque gradient curve 50 a (e.g., by way ofa running average). These values (torque, rotation, and torque gradient)may then be plotted by the plotter 232 for display on the output device220.

The values (torque, rotation, and torque gradient) may then be comparedby the connection evaluator 252, either continuously or at selectedevents, with predetermined values, such as the values 223-230. Based onthe comparison of the measured and/or calculated values with thepredefined values 223-230, the process monitor 234 may determine theoccurrence of various events and the connection evaluator 252 maydetermine whether to continue rotation or abort the makeup. The threadengagement detection algorithm 244 may monitor for thread engagement ofthe pin 8 and box 10. Upon detection of thread engagement a first markeris stored. The marker may be quantified, for example, by time, rotation,torque, the torque gradient, or a combination of any suchquantifications. During continued rotation, the seal detection algorithm246 monitors for the seal condition. This may be accomplished bycomparing the calculated torque gradient with a predetermined thresholdseal condition value. A second marker indicating the seal condition maybe stored if/when the seal condition is detected. At this point, thetorque value at the seal condition may be evaluated by the connectionevaluator 252.

For example, a determination may be made as to whether the turns valueand/or torque value are within specified limits. The specified limitsmay be predetermined, or based off of a value measured during makeup. Ifthe connection evaluator 252 determines a bad connection, rotation maybe terminated. Otherwise, rotation continues and the shoulder detectionalgorithm 248 monitors for the shoulder position. This may beaccomplished by comparing the calculated torque gradient with theshoulder threshold gradient 224. When the shoulder position is detected,a third marker indicating the shoulder position is stored. Theconnection evaluator 252 may then determine whether the torque value atthe shoulder position is acceptable by comparing to the respective inputtorque values 230.

Upon continuing rotation, the target detector 254 compares the measuredtorque to the dump torque value 226. Once the dump torque value 226 isreached, rotation may be terminated by sending the dump signal 222.Alternatively, the dump signal 222 may be issued slightly before thedump torque 226 is reached to account for system inertia. Once theconnection is complete, the connection evaluator 252 may calculate adelta turns value based on the difference between the final turns valueand the turns value at the shoulder condition. The connection evaluator252 may compare the delta turns value with the input delta turns values228. Similarly, the connection evaluator may compare the final torquevalue to the respective input torque values 230. The connectionevaluator 252 may calculate a delta torque value based on the differencebetween the final torque value and the torque value at the shouldercondition. The connection evaluator 252 may calculate a delta gradientvalue using delta torque and delta turns values and compare it with therespective input values 223. If either criteria is not met, then theconnection evaluator 252 may indicate a bad connection.

Alternatively, a delta turns value may be entered instead of the dumptorque 226. The target detector 254 may then calculate a target turnsvalue using the shoulder turns and the delta turns value (target turnsequals shoulder turns plus delta turns).

Although a tong system is described with respect to FIGS. 1-3, othersystems can be used for tubular makeups, such as a top drive system.These systems can also include graphical evaluators for monitoring theconnections.

As mentioned above, the example tubular makeup system 200 includespredetermined values 223-230 input by a technician or operator. Wronginputs of the measured values may lead to incorrect calculated torquevalues which, in turn, may lead to under torque or over torque, and maybe without any warning. In order to reduce the possibility of humanerror and to increase efficiency, it is desirable to automate theprocess of monitoring threaded connections, evaluating the quality ofthreaded connections, and controlling the assembly system.

In some cases, a drop down menu has been added to the operator inputinterface (e.g., input device 218). The drop down menu provides a finiteselectable list of load cell identification information, which can helpto reduce the likelihood of wrong inputs—but does not eliminate thepossibility.

Aspects of the present disclosure provide techniques and apparatus forautomated (i.e., hands-free) load cell identification which may reducethe amount of information that is input manually and thereby, reduce thepossibility for wrong inputs in the torque calculation.

Example Automated Load Cell Identification

FIG. 4 illustrates an example tubular makeup system 400 including a loadcell that sends load cell identification information, in accordance withcertain aspects of the present disclosure. In aspects, the load cell maysend its identification, type, torque range, and/or calibrationinformation. Tubular makeup system 400 may include a power drive 402,one or more load cells 404 (e.g., similar to torque cell 212), and aremote processing system 406 (e.g., similar to tong remote unit 204 orcontrol system 206) that includes a server 408, and a client 410.

The power drive 402 may be a tong assembly (e.g., similar to tongassembly 100), over drive system, or other makeup tool for connectingcasing, tubulars, etc. The load cell 404 may be coupled to the powerdrive 402 and configured to measure data related to force applied to aconnection during makeup.

The load cell 404 may include interfaces for communicating with anotherdevice. For example, the load cell 404 may include a two-wire, 4 . . .20 mA serial interface 414 used for transmitting force data. The loadcell 404 may include an additional interface which may be use forsending the load cell identification information. The load cell 404 maybe communicatively coupled with the remote processing system 406 via theinterface. One example of the remote processing system 406 includesJoint Analysis and Makeup (JAM) devices, such as the JAMCompact™ torquemonitoring system by Weatherford, Inc. The remote processing system 406may also have an interface that supports serial communication on twochannels.

The load cell 404 may send a 4 . . . 20 mA signal representing themeasured force over the interface 414 to the remote processing system406. For example, the 4 . . . 20 mA signal may be sent to the server408. The force data may be sent (e.g., permanently) during the makeupprocess to provide information regarding force applied to the threadedconnection during the makeup. The server 408 may provide the force datato the client 410. One example of the client 410 includes a JAM client,such as the TorkPro™ torque/turn analyzing software by Weatherford, Inc.The client 410 may calculate torque values based on the force data. Thecalculated torque values can then be used to evaluate the connection,output a graphical display, make control decisions for power drive 402,etc.

In one aspect, the server 408 may be a stand-alone computer. The server408 may include a storage unit (e.g., similar to storage device 221) forstoring data for operations, such as data for each makeup or break out.Alternatively, the server 408 may be a storage unit in the remoteprocessing system 406. The client 410 may be a terminal computer thatmay be remote from the server 408, or could be the same computer. Theclient 410 may be a mobile unit, such as a tablet, that allowsoperations at flexible locations.

Certain load cells have a variety of available measurement ranges and avariety of calibration settings. For example, some load cells have fiveavailable ranges. Conventionally, the range of the force are determined(e.g., looked up) based on datasheets and the values are enteredmanually into the client 410 by the operator/technician. According tocertain aspects of the present disclosure, however, load cellidentification information may be determined automatically by the remoteprocessing system 406. For example, the load cell 404 may be configuredto send the load cell identification information via a serial interface412. The interface 412 may be an additional interface on the load cellamplifier, along with a microcontroller. As shown in FIG. 4, the loadcell 404 can send the load cell identification information on the serialinterface 412 and can send the force data (e.g., torque measurements) on4 . . . 20 mA interface 414. The load cell identification informationmay include the load cell identification, type, calibration data,measurement torque range, etc. In aspects, the load cell 404 may sendthe load cell identification information over the serial interface 412before makeup of the connection. The remote processing system 406, mayread the identification information to ensure that the load cell isvalid for this connection. For example, the load cell torque range maybe compared to a job defined torque value or range.

Once the remote processing system 406 verifies that the load cell isvalid for the connection, the remote processing system 406 may begin themakeup of the connection. During the makeup process, the load cell maysend force data via the 4 . . . 20 mA interface 414. The remoteprocessing system 406 may use the torque range information and the forcedata sent by the load cell 404 to calculate torque values during themakeup process. As shown in FIG. 4, the power drive 402 may also providenumber of turns data to the remote processing system 406 (e.g., via aturns counter similar to turns counter 208) which may also be providedto the client 410. The client 410 may use the load cell identificationinformation, force data, and number of turns data to evaluate aconnection. In some cases, the client 410 may perform an automatedevaluation. In some cases, the client 410 may output a display (e.g., agraphical display) and an operator/technician can evaluate theconnection. An input control from the operator/technician or anautomated control decision from the client 410 can be sent from theprocessing system 406 to the power drive 402. In one example, the client410 may compare the information with job defined set points and createan error message to prevent a wrong set up.

According to certain aspects, parameters provided by the load cell(e.g., the load cell identification information) may include theavailable measurement ranges and calibration settings, store/restorefactory settings for each measurement range, return load cell range, setautomatic mode on/off, set tension or compression direction, setindividual load cell serial number, storing values for temperaturecompensation, storing load cell programming date, storing load cellhardware revision, return load cell firmware version, and return loadcell part number. Load cell identification information sent by the loadcell 404 over the interface may include the load cell (e.g.,manufacturer), the load cell serial number, the load cell measurementrange, the load cell manufacturing date, the load cell accuracy, and/orcalibration information for the load cell (e.g., calibration factors,offset, date of last calibration, next calibration date, name ofcalibration service, name of inspector, ambient temperature, hardwareversion and date, software version and date).

According to certain aspects, the load cell 404 includes a load cellamplifier having the serial interface, the 4 . . . 20 mA interface and amicrocontroller on board. The identification information data transferover the two wired interface may be performed in a unidirectional masterslave mode. The master software may be located at the remote processingsystem 406. Read and write operations may be controlled by the server408. The slave firmware may be implemented in the load cell 404amplifier.

According to certain aspects, the force data and/or load cellidentification information can be sent from server 408 to the client 410in response to a request. For example, the client 410 may send a requestto the server 408 for the force data and/or load cell identificationinformation and server 408 can send the force data and/or the load cellidentification information in response to the request.

According to certain aspects, the load cell 404 may be configured tooperate with or without the enhanced features (e.g., without sending theload cell identification information). FIG. 5 is a block diagramillustrating example operations 500 of the (enhanced) load cell 404illustrated in FIG. 4, in accordance with certain aspects of the presentdisclosure. As shown in FIG. 5, at 502, the load cell 404 may beinitialized (e.g., with I/Os, Register, and the 2-wire serialinterface). At 504, the load cell 404 performs force measurements (e.g.,using strain gauges) and outputs the corresponding 4 . . . 20 mA signalrepresenting the measurements via the interface. At 506, the load cell404 can determine whether it is operating under the old protocol or theenhanced protocol. If the load cell 404 is operating under the oldprotocol, the load cell 404 sends the force data and executes a commandfunction at 508 and then repeats measurements 504. If the load cell 404is operation under the enhanced protocol, then, at 510, the load cell404 may receive read/write address command from the remote processingsystem 406 that requests the data and the load cell identificationinformation and, at 512, the load cell 404 sends the force data and theload cell identification information over the serial interface. Forexample, the load cell 404 can receive a read request from theprocessing system 406 (e.g., from the server 408 or the client 410) thatindicates an address for the requested load cell identificationinformation.

According to certain aspects, the read request may be sent/receivedusing a customized Modbus protocol. Modbus is a command based serialcommunication protocol. Following the Modbus protocol, the load cell 404can receive single characters until an end of transmission isidentified. The load cell 404 may translate received commands andexecute a program function based on the commands. For example, tencharacters (e.g., bytes) can be received via the serial interface in onedata block. The ten bytes may include a start byte, a 2 byte address, afunction byte, a data length byte, four bytes of data, and a checksumbyte (e.g., a longitudinal redundancy check (LRC)). The values of thefunction byte can indicate a read request, a write request reading ok,writing ok, or an error code. The error codes may indicate an unknownfunction, unknown address, invalid value, hardware error, checksumerror, writing without permission, frame not complete error or syncerror (invalid start byte).

FIG. 6 is a flow diagram illustrating example operations 600 forconnecting a first threaded tubular to a second threaded tubular, inaccordance with certain aspects of the present disclosure. Theoperations 600 may be performed by a tubular makeup system. Theoperations 600 includes, at 602, sending, from the load cell to a remoteprocessing system, identification information associated with the loadcell (e.g., via the serial interface). At 604, the method includesdetermining whether the load cell is valid for use during makeup of athreaded connection of a first threaded tubular to a second threadedtubular based on the identification information associated with the loadcell. As shown in FIG. 6, the determination may include, at 604A,comparing the measurement range of torque values to a job defined rangeof torque values associated with the makeup of the threaded connectionand, at 604B, determining that the load cell is valid for use based onthe comparison. After determining the load cell is valid, the tubularmakeup process may be performed, for example, as shown in steps 606-616.At 606, the threads of the first threaded tubular may be engaged tothreads of the second threaded tubular. At 608, the first threadedtubular is rotated relative to the second threaded tubular, therebymaking up the threaded connection. At 610, during makeup of the threadedconnection force data applied to the threaded connection is measuredusing the load cell. At 612, during the makeup of the threadedconnection, the measured force data is sent from the load cell (e.g.,via the 4 . . . 20 mA interface) to the remote processing system. At614, torque applied to the connection is calculated, at the remoteprocessing system, based on the force data and the identificationinformation (e.g., based on the measurement torque range information).At 616, the threaded connection is evaluated based, at least in part, onthe calculated torque.

According to certain aspects, different techniques can be used forautomated load cell identification. For example, the load cellidentification information can be sent via the coded 4 . . . 20 mAsignal on power up. As another example, a barcode or radio frequencyidentification (RFID) can be used to obtain the load cell identificationinformation. For example, the load cells can be tagged with the barcodeor RFID tag and a scanner may be used to scan the barcode or RFID tag.In yet another example, a beacon can be transmitted, for example usingBluetooth technology that includes some load identification information.In yet another example, a Highway Addressable Remote Transducer (HART)protocol can be used by adding a frequency modulated data signal to the4 . . . 20 mA signal to send load cell identification information. Inyet another example, the IEEE 1451.4 Standard for Smart Transducers canbe used for a “plug and play” approach to sending the load cellidentification information.

While the foregoing is directed to embodiments of the presentdisclosure, other and further embodiments of the disclosure may bedevised without departing from the basic scope thereof, and the scope ofthe invention is determined by the claims that follow.

The invention claimed is:
 1. A method, comprising: sending, from a loadcell to a remote processing system, identification informationassociated with the load cell; determining whether the load cell isvalid for use during makeup of a threaded connection of a first threadedtubular to a second threaded tubular based on the identificationinformation associated with the load cell; engaging threads of the firstthreaded tubular to threads of the second threaded tubular; rotating thefirst threaded tubular relative to the second threaded tubular, therebymaking up the threaded connection; during makeup of the threadedconnection: measuring force data applied to the connection using theload cell; and sending, from the load cell to the remote processingsystem, the measured force data, wherein: sending the measured forcedata comprises sending the measured force data via a first interfacebetween the load cell and the remote processing system; and sending theidentification information comprises sending the identificationinformation via a second interface between the load cell and the remoteprocessing system; calculating, at the remote processing system, torqueapplied to the connection based on the force data and the identificationinformation associated with the load cell; and evaluating the threadedconnection based, at least in part, on the calculated torque.
 2. Themethod of claim 1, wherein: the load cell identification informationincludes a measurement range of torque values supported by the loadcell; and determining the load cell is valid for use during the makeupof the threaded connection comprises: comparing the measurement range oftorque values to a job defined range of torque values associated withthe makeup of the threaded connection; and determining that the loadcell is valid for use based on the comparison.
 3. The method of claim 1,wherein: the first interface comprises a 4 . . . 20 mA interface; andthe second interface comprises a serial interface.
 4. The method ofclaim 1, further comprising: receiving, at the load cell, a request fromthe remote processing system for the identification information, whereinthe identification information is sent in response to the request. 5.The method of claim 1, further comprising: sending the force data andidentification information to a client of the remote processing system,wherein the evaluating is performed by the client.
 6. The method ofclaim 1, wherein the identification information comprises at least oneof: an identification of the load cell, a type of the load cell, a forcemeasurement range of the load cell, a measurement accuracy of the loadcell, a manufacturing date of the load cell, a serial number of the loadcell, or calibration information associated with the load cell.
 7. Atubular makeup system, comprising: a load cell; a remote processingsystem in communication with the load cell, wherein: the load cell isconfigured to send identification information associated with the loadcell to the remote processing system; and the remote processing systemis configured to determine whether the load cell is valid for use duringmakeup of a threaded connection of a first threaded tubular to a secondthreaded tubular based on the identification information associated withthe load cell; a power drive operable to rotate the first threadedtubular relative to the second threaded tubular thereby making up thethreaded connection, wherein: the load cell is configured to, duringmakeup of the threaded connection: measure force data applied to thethreaded connection; and send, to the remote processing system, themeasured force data; and the remote processing system is furtherconfigured to: calculate torque applied to the threaded connection basedon the force data and the identification information associated with theload cell; and evaluate the threaded connection based, at least in part,on the calculated torque; and a first interface and a second interfacebetween the load cell and the remote processing system, wherein the loadcell is configured to: send the measured force data via the firstinterface; and send the identification information via the secondinterface.
 8. The tubular makeup system of claim 7, wherein: the loadcell identification information includes a measurement range of torquevalues supported by the load cell; and the remote processing system isconfigured to: compare the measurement range of torque values to a jobdefined range of torque values associated with the makeup of thethreaded connection; and determine that the load cell is valid for usebased on the comparison.
 9. The tubular makeup system of claim 7,wherein: the first interface comprises a 4 . . . 20 mA interface; andthe second interface comprises a serial interface.
 10. The tubularmakeup system of claim 7, wherein the load cell is further configuredto: receive a request from the remote processing system for theidentification information; and send the identification information inresponse to the request.
 11. The tubular makeup system of claim 7,wherein the remote processing system is further configures to: send theforce data and identification information to a client of the remoteprocessing system; and evaluate the threaded connection at the client.12. The tubular makeup system of claim 7, wherein the identificationinformation comprises at least one of: an identification of the loadcell, a type of the load cell, a measurement range of the load cell, ameasurement accuracy of the load cell, a manufacturing date of the loadcell, a serial number of the load cell, or calibration informationassociated with the load cell.